Methods for production of food batter materials

ABSTRACT

A batter mixing apparatus and process is disclosed for mixing a dry batter mix with a predetermined amount of water is adapted to continuously measure the temperature and the viscosity, in centipoises, with an inline viscometer. The controls of the apparatus are fully automated using a programmable logic controller in conjunction with a touchscreen display that provides real-time data, process control parameters, and a choice of batter recipes. Once the batter has reached a desired viscosity, a variable speed feed pump is used to pump the batter to a batter applicator where a food product is coated. Excess batter from the applicator is collected and returned to the mixing apparatus via a pump. The viscosity and temperature of the returned batter is measured and adjusted automatically with dry batter mix or water in order to satisfy the set parameters.

CROSS REFERENCE

This application is a Divisional of co-pending U.S. application Ser. No.10/969,763 filed Oct. 20, 2004, which is based on Provisional U.S.Application Ser. No. 60/512,899 filed Oct. 21, 2003, each of which arehereby incorporated herein by reference.

TECHNICAL FIELD

This invention relates to a system and process for mixing materials intoa substantially homogenous product, such as a batter material. Moreparticularly, the invention relates to a system and method for mixingmaterials to form a product having a desired viscosity profile, and mayinclude the continuous measurement of the actual viscosity of theproduct.

BACKGROUND OF THE INVENTION

In the food processing industry as an example, various devices andprocesses have been developed for preparing coated food products. Forexample, in large-scale food processing environments, the food productsmay be battered and breaded using in-line processing equipment. The foodproducts are introduced to a batter applicator machine and dipped orotherwise coated with a batter having a desired formulation andconsistency. Thereafter, the food products may be breaded, fried orotherwise processed as desired. The batter applicator is supplied withan amount of batter material from a mixing machine to as to allow forcontinuous processing of food products passing therethrough. Althoughbatter mixing apparatus have been developed for this purpose, theexisting apparatus do not allow effective control over batter viscosityand temperatures to provide a consistent and repeatable batter material.It would therefore be desirable to provide a system and methods forproducing batter having predetermined characteristics and attributes, toallow proper coating and preparation of food products in an in-lineprocessing system.

Batter mixing equipment previously developed also operated in anisolated fashion, with an operator controlling the functions of themixing machine and therefore the quality of batter produced thereby. Itwould therefore be desirable to provide a system and methods to allowoperation of a batter mixing machine in a manner such that the machineis integrated into an overall processing system, and to allowcentralized control and monitoring of machine function.

In prior batter mixing systems, an amount of a dry mix material iscombined with water to form a desired batter. The amount of dry mixformulation and water or other ingredients must be accurately mixed andmaintained at a desired temperature to provide a batter havingpredetermined characteristics to provide desired coating of foodproducts. Depending on the food products, the batch of dry mix material,the local environment and other factors, the predeterminedcharacteristics can vary. The system must accurately and continuouslymix the ingredients to form the desired batter, or the final productwill vary in appearance, weight and taste. In prior systems therefore,the operator was required to be relatively skilled to monitor theoperation to ensure proper mixing. If problems in the batter occur, itis typically only when the battered food products have been furtherprocessed, and the final product is not in compliance with predeterminedquality control standards. It would therefore be desirable to allowselective control of the batter mixing system based on direct feedbackfrom further processing steps or independent of an operator.

In this regard, prior systems have required manual monitoring of theconsistency of the batter produced to attempt to maintain the desiredbatter characteristics. Instruments or methods for relative theviscosity of a product have been developed. Depending on the nature ofthe product and the viscosity, such methods vary. In the environment oflarge scale food processing, the batter consistency is generally ofintermediate viscosity and monitoring is typically performed by the Zahncup method. In this method, a relative viscosity is measured by thenumber of seconds it takes for a measured amount of product to flow outof a Zahn cup, which is a container with a hole in the bottom. Zahn cupsare graded by the size of the hole. In such a technique, the measurementis somewhat subjective, and depending on the user, wide variations inreadings are possible for the same batter mix. The Zahn cup measurementtechnique simply does not provide a reliable and repeatable measure ofviscosity. Further, such a technique only provides a relative viscosityand does not provide any precise control parameter for the batter mixingoperation. Other viscosity measuring techniques have been developed forfluids, depending on the nature of the fluid.

Additionally, with respect to a batter material for use in a large scalefood processing environment, the above mentioned method of utilizing aZahn cup to provide a relative measure of viscosity, is typically usedwhen a batter is initially mixed. It is known that when a batter isfirst mixed, it exhibits different characteristics than most liquids.This is due to the mixture behaving more like a suspension of solids,rather than a true liquid. An operator who works a batter mixertypically has to test the viscosity of the batter at certain timeintervals in order to know when the batter has become a homogeneousproduct. This process is time consuming and can result in a batter witha varying viscosity, particularly if different operators read the Zahncup measurements differently.

It would therefore be desirable to provide a batter mixing system withthe ability to accurately measure the actual viscosity of the batter orother material. More specifically, it would be desirable to provide amixing system with an in-line viscometer used in conjunction with aprogrammable control system for the purposes of monitoring andcontrolling the production processes involved in a batter mixing system.

SUMMARY OF THE INVENTION

Based upon the foregoing, the present invention provides an apparatusand methods for mixing of a materials and controlling actual viscosityduring the mixing process. The apparatus and methods overcome thelimitations found in the prior art, and enable more precise monitoringand control of the production processes involved in a mixing system.

An object of the invention is therefore to provide a mixing apparatusand methods wherein the actual viscosity is monitored and controlledusing an in-line viscometer to provide actual viscosity measurements.Another object of the invention to provide an apparatus for controllingviscosity, which provides a real-time viscosity measurement incentipoises. It is a further object of the invention to provide anapparatus for controlling viscosity, which provides a temperaturecontrol system for effectively controlling the temperature of themixture, comprising a jacketed fluid heat exchange circulation system.The invention may also provide a control system, which may beprogrammable and integrated into a centralized process control foroperation of the apparatus. Other advantages and attributes are alsoprovided according the apparatus and methods of the invention.

In general, the invention is directed to an apparatus for controllingviscosity during mixing of at least a first and a second component. Asource of the at least first and second components provides apredetermined amount of the components to a mix tank. A mixer isprovided to mix the components into a substantially homogeneous productduring a mix cycle. An in-line viscometer is coupled to the mix tank toreceive a supply of the product therefrom, and provides an indication ofthe products actual viscosity. A control system controls the supply ofthe at least first and second components and the mix cycle tosubstantially maintain a predetermined viscosity.

The invention is also directed to a method for mixing of at least firstand second components, wherein predetermined amounts of the at leastfirst and second components are mixed into a substantially homogenousproduct. The product is selectively supplied to an in-line viscometer,which provides an indication of the products actual viscosity, and atleast the supply of the first and second components is controlled tosubstantially maintain a predetermined actual viscosity.

Other objects and aspects of the present invention will be apparent uponreview of the specification, drawings, and claims appended hereto.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of a mixing apparatus according to an embodiment ofthe present invention, in conjunction with a batter applicator used in afood processing system.

FIG. 2 is a front view of a mixing apparatus according to an embodimentof the present invention.

FIG. 3 is a side perspective view of the mixing apparatus as shown inFIG. 2.

FIG. 4 is an enlarged partial front view of the mixing apparatus asshown in FIG. 2, according to an embodiment of the present inventionshowing the continuous supply of batter to an in-line viscometer system.

FIG. 5 is an enlarged partial top cross-sectional view of the in-lineviscometer used in the mixing apparatus of the present invention.

FIG. 5 a is a partial front view of the filtering system and protectionsystem on the inlet of the viscometer used in an embodiment of theinvention.

FIG. 6 is an enlarged partial view of a component supply system alsoserving to provide a self-cleaning function in the apparatus.

FIG. 7 is a block diagram of an embodiment of the control system of thebatter mixer apparatus of the present invention.

FIGS. 8 a-c shows flow charts indicating function of the control systemin operating the mixing apparatus according to an embodiment of thepresent invention.

FIG. 9 a-b shows generally schematic diagrams of an embodiment of theinvention, with a plurality of mixing apparatus networked to a centralcontrol system in accordance with the invention.

DETAILED DESCRIPTION OF THE INVENTION

With reference to FIG. 1, an in-line processing system is shown toinclude a mixing system 10 according to an embodiment of the invention.The mixing system 10 may be used in a large-scale food processing systemfor example, to prepare a batter for coating of food products. In suchan embodiment, the batter mixing apparatus 10 prepares a batter with asubstantially constant specified viscosity, viscosity profile or range.The batter is then supplied via supply piping 51 to at least one batterapplicator 50, as needed to form a pool of batter material 52 in whichfood products traveling on conveyor 54 are dipped and coated. The foodproducts in many cases will be breaded prior to the application ofbatter, such as with flour pre-dusting or the like. Once the foodproduct is coated with batter, it is conveyed to further processingequipment 60, such as a breading machine, an oven, fryer, or otherequipment in an in-line processing system. Typically, the processingwill include cooking or frying of batter/breaded food products, as wellas subsequent freezing and packaging for preparing the product for sale.

As it is desired to coat the food products with a desired battermaterial which results in desired final product characteristics, it ishighly desirable to maintain the characteristics of the batterformulation, particularly its viscosity. As food products being dippedin the pool 52 will cause changes in the batter characteristics withinthe pool 52, the present invention may provide recirculation of thebatter from pool 52 to the mixing system 10, via return piping 55.Alternatively, as will be explained in more detail hereafter, the battersupplied to the applicator 50 may be on an as needed basis, with thelevel of the pool 52 monitored and used to selectively pump batter toapplicator 50. In this way, the batter is maintained as a substantiallyhomogenous product having predetermined characteristics. Thecharacteristics of the batter result in a predetermined pick up ofbatter at the batter applicator 50 by food products being coated. It isdesirable to maintain a predetermined pickup for efficiently coatingfood products and maximizing yield while minimizing costs. The mixingapparatus 10 can be precisely controlled in response to feedback controlsignals to ensure the desired pickup. For example, once the product iscoated at the applicator 50, the actual pickup may be monitored, eithermanually or automatically, and control signals provided to the mixingapparatus 10 for control of the viscosity and therefore the desiredpickup. Control functions and interface with other processing equipmentwill be described in more detail hereafter.

The mixing apparatus 10 according to an embodiment of the presentinvention is shown in more detail in FIGS. 2 and 3. The apparatus 10comprises a mixing tank 14, in which materials to be mixed areselectively introduced. In general, the mixing tank 14 is supplied withan amount of a dry batter mix material, along with an amount of water toform a batter having predetermined characteristics. In this embodiment,the tank 14 is configured to keep the mixture therein at substantially apredetermined temperature, without interference within the tankinterior, which will be described in more detail hereafter. Controllingthe temperature of the batter, as it is being mixed and supplied to thebatter applicator is important to maintain the desired viscosity andbatter characteristics. The apparatus 10 also includes a control system,generally designated 16, that in this embodiment may comprise aprogrammable logic controller (PLC). A touch screen display 18 is usedto operate the control system 16. A viscometer control panel 24,providing user interfaces for operation and monitoring of the viscometer21. The PLC control system 16, such as a programmable logic controller(PLC), is programmed to perform various operations in conjunction withthe mixing and supply of materials by apparatus 10. The PLC 16 is alsosupplied with information from a plurality of sensors so as tocontinually monitor the operation of the apparatus 10, and supply andmixing cycles associated therewith. The control system 16, for example,monitors actual viscosity of the batter or other material in tank 14, incentipoises, by means of the inline viscometer 21. The control panel 24may provide a visual representation of viscosity measured by viscometer21, to allow a user to monitor the viscosity continuously and makeadjustments when they are required. The control system 16 also monitorsthe temperature of the batter in the mixing apparatus with a temperatureprobe 22. Other temperature sensors may be used to supply the controlsystem 16 with temperature data, such as in association with the batterapplicator or at other locations. Other sensors or monitoring ofadditional aspects of the operation of apparatus 10 is alsocontemplated, such as the operation of pumps, fill and feed systems forconstituents to be mixed, mixer operation, and the like.

The batter is mixed in tank 14 by means of a high speed mixing head 34,which is selectively disposed in tank 14, into a substantiallyhomogenous product having predetermined characteristics that arethereafter maintained. As an example, a suitable mixing head 34 has beenfound to be a stainless steel 2 hp mixer produced by Admix, Inc. Such amixer 34 may operate at high speeds, such as 1750 rpm, as compared toprior systems having much slower mixing speeds. The mixer 34 motor maybe operated by a variable frequency drive to allow flexibility in themixing characteristics of the system. For example, with some battermaterials, it is possible to “overmix” the batter, causing degradationof desired characteristics. The ability to vary the mixer speed allowsproper mixing characteristics to be achieved for the particularmaterials to be mixed. Higher mixing speeds may promote the break up ofclumps or the like, and also facilitates the thermal treatment of thebatter or other material by means of a thermal treatment system as willbe hereinafter described, for chilling or heating the product in tank14. Providing this and other components of the machine 10 in stainlesssteel or other sanitary materials facilitates use in the food processingindustry or the like.

During the batter mixing operation, the batter being produced in tank14, is selectively or continuously pumped to the inline viscometer 21via a pump 26. The pump 26 may be a stainless steel viscosity pump andmotor with direct drive, such as produced by Waukesha Cherry-BurrellCompany. The pump 26 may be operated by a variable frequency drive tocontrol flow to viscometer 21 as desired. The inline viscometer 21measures the actual viscosity of the batter, in centipoises and inreal-time, and the batter is then returned to the tank 14 before beingpumped to the batter applicator 50.

To facilitate the initial formulation of the batter, a dry batter mix isprovided in a dry mix hopper 28, having a capacity of 100 pounds forexample. Desirably, the hopper 28 is situated at a relatively lowheight, which in the embodiment shown is positioned at a 53″ feedheight, to simplify dispensing batter mix therein. Once the mix cycle ofthe batter mixer has been started, a water supply line 31 fills the tank14 with water until the water reaches a minimum level probe 32 that isfound on the interior of the tank 14. When the water reaches a minimumlevel probe 32, the mixing motor 34 may be activated, which rotates amixing head at a desired speed inside the mixing tank 14. The dry battermix is then fed from the hopper 28 into the mixing tank via a feedconveyor 29 (shown in FIG. 1). The viscosity pump 26 is then activatedand begins to measure the viscosity of the water and mix material in themixture. In the case of a batter material, continued mixing forms asubstantially homogenous product from the feed materials. A thermaltreatment system 15 is used to circulate heat exchange fluid in thejacketed portions 17 of tank 14, to cool (or heat) the batter or otherhomogenous product material to a predetermined temperature during themixing cycle. Upon additional mixing, and once the appropriate viscosityand temperature are reached, additional water and dry batter mix may beadded to the mixing tank 14 until a high level probe is reached. At thispoint in time, the water and the dry batter mix addition are stoppedwhile the viscometer pump 26 continues to supply the viscometer 21 withmaterial to measure the viscosity. If the mixture is too thick,additional water will be added to the tank in order to achieve thepredetermined or set viscosity. Likewise, if the mixture is too thin,additional dry mix batter will be added to the tank in order to achievethe set viscosity. Once batter having the predetermined characteristicsis achieved, an amount of batter may be pumped to the applicator 50 orother location for use, via a sanitary stainless steel feed pump 12 andmotor with direct drive. The pump 12 may be operated with a variablefrequency drive for speed and flow control, with operation of pump 12,as well as supply pump 26, provided by pushbutton control. Providing avariable frequency drive for operating pump 12 is preferred because ofthe flexibility in controlling supply of batter therewith. In alarge-scale food-processing environment, a large number of pounds perhour may be coated, requiring a constant supply of batter to pool 52. Abatter level monitor or sensor may be provided at applicator 50 tomonitor the depth of pool 52 and maintain a needed supply of batter topool 52 via control system 16 and variable frequency drive associatedwith pump 12. Any desired pumping volumes can be achieved by suitablecontrol of the pump 12 by the control system 16. This eliminates theneed for a pump and bypass line, which has been used in prior mixingdevices using a fixed speed drive, to pump batter back to the mixingmachine when no further batter is required at the applicator 50 or thelike. Other control signals may be supplied from the applicator 50 orthe like to allow selective control of apparatus 10. In the event thatprocessing does not require constant refreshing of batter to pool 52 tomaintain proper levels, it still may be desirable according to theinvention to pump the batter from the pool 52 back to the mixingapparatus 10 and maintain a fresh supply of batter to pool 52. As pool52 may be contaminated by breading materials, pieces of the foodproducts themselves, water on the product, or other materials from foodproducts passing through pool 52, the viscosity of the batter within thepool 52 can change. By pumping the batter from pool 52 back to theapparatus 10, and in turn supplying fresh batter to the pool 52therefrom, the batter characteristics in the pool are maintained in amore uniform manner.

As previously mentioned, the mixing apparatus 10 according to thisembodiment comprises a thermal treatment system, generally designated15, to maintain the batter or other material at a predeterminedtemperature. As an example, the thermal treatment system 15 of thepresent invention may comprise a jacketed mixing tank, with jacketedportions 17 along the sides and/or bottom of the mixing tank 14. In pastsystems, a fluid heat exchanger having piping through which a heatexchange fluid was pumped was situated in along the tank walls,extending as ribs on the interior of a mix tank. Additionally, in manycases, the fluid heat exchangers of prior systems were not sufficient tocool the batter material to the desired temperature, thus requiring asupplemental heat transfer coil, usually positioned in the bottom of thetank. In these past configurations, the piping on the interior of thetank and/or the supplemental system, presented an obstacle orinterference within the tank that adversely affects mixing of theconstituents within the tank. Further, such systems presented adifficulty in cleaning of the equipment, due to the large amount ofsurface area exposed on the interior of the tank, which the batter is incontact with. Additionally, the interior of the tank was not smooth,which tends to impede the flow of batter adjacent thereto, therebycausing freezing of batter adjacent the tank walls, and non-uniformcooling of the batter.

In the present invention, the tank 14 is designed to have a polished,smooth interior surface, which allows efficient, and less restrictedmovement of materials in the mixing process. The thermal treatmentsystem 15 is provided by forming tank 14 with jacketed portions 17. Thejacketed portions 17 may be formed by interior and exterior walls, whichare welded at intervals to create channels between the walls in which athermal fluid for heat exchange with the batter can flow. The interiorwall of the jacket forms the interior of tank 14, so as to be directlyexposed to the batter therein, but without any interference within thetank volume. Water, ammonia, glycol, combinations thereof, or anothersuitable heat exchange fluid, are circulated through the channelslocated within the jacketed portions 17, thereby cooling and maintainingthe batter, as it is constantly mixed, at a predetermined temperature.The jacketed portions 17 integrated into the tank 14 further provide inconjunction with the mixer, a swept surface heat exchanger that preventsthe mixing tank from icing during the batter mixing. Icing of the tank14 can cause significant problems, but the heat transfer provided by thethermal treatment system and the high speed mixing of the materialswithin tank 14 by the mixer 34 efficiently transfers heat between thematerials in the tank 14 to minimize or eliminate freezing of theexterior of tank 14 and/or freezing of batter material adjacent theinterior surface of tank 14.

The mixing apparatus 10 of the present invention may be further equippedwith an alarm system which may comprise a visual alarm indicator 36, aswell as producing an audible alarm if machine functions are out ofspecifications. The visual alarm system 36, for example, may have threecolored lights, green, yellow, and red, that indicate the current statusof the mixing apparatus 10. When the alarm system 36 is lit green, allparameters, such as viscosity, batter temperature, incoming thermaltreatment fluid temperature, batter levels in tank 14, amounts of drybatter mix in hopper 28, the supply and temperature of incoming fillwater, the status of the viscometer pump 26, the status of the feed pump12, and many other parameters relating to operation of the machine 10,are within specification. If the alarm system 36 is lit yellow, thenthis indicates that at least one of the parameters is out ofspecification and needs to be corrected in order to ensure proper batterproduction. If the alarm system is lit red, then this indicates that oneof the parameters needs immediate attention before proceeding with themixing of the batter. As the various operation parameters can each havean adverse impact upon proper mixing and maintenance of the batterproduct, the ability to monitor each of these and allow effectiveresponse should a problem occur, provides significantly improvedoperation in conjunction with the overall processing system.

FIG. 4 is an enlarged view of the batter mixing apparatus 10 showing thecirculation of material from the tank 14 through the inline viscometer21. The direction of the arrow shows the path of the material, such as abatter, as it is circulated through the inline viscometer 21 andreturned to the mixing tank 14. The circulation of material may beconstant or intermittent as desired. In a preferred embodiment, thevariable speed viscometer pump 26 housed under the mixing tank 14continuously recirculates fresh batter through the inline viscometer 21.This allows the inline viscometer 21 to continuously measure theviscosity of the batter. Intermittent pumping of batter through theinline viscometer 21 may alternatively provide measurements at selectedtimes. The viscosity is thereby monitored by the viscometer 21 anddisplayed, with the PLC control system 16 automatically adjusting themix and mixer operation accordingly, in order to maintain the programmedviscosity set point.

Turning to FIG. 5, a cross-sectional view of the inline viscometer 21 isshown, wherein piping from the mix tank 14 supplies an amount of batterto the housing 23 via pump 26 as previously described. In thisembodiment, the inline viscometer 21 is desirably of any suitableconfiguration to allow actual viscosity measurement in centipoises. Forexample, a suitable viscometer is produced by Brookfield Engineering,Inc., Model AST-100, wherein an ultrasonic probe is used to obtain adirect measurement of viscosity for a fluid in contact therewith. Asseen in FIG. 5, the viscometer 21 may position the probe 25 within ahousing 23, in a manner, which allows the batter or other material toflow fully around the probe in the circulation path. The ultrasonicprobe 25 may be positioned in the center of housing 23 and spaced fromthe interior wall thereof, forming a channel 27 around the probe 25. Asbatter flows into housing 23, it will flow around the probe 25,contacting the probe as it flows though housing 23, and providing anaccurate actual viscosity measurement that is supplied to control system16. In this embodiment, the housing arrangement and supply of materialto inline viscometer 21 is performed with minimal to no pressure dropacross the sensor housing 23. Additionally, the sensor housing 23 may behermetically sealed to avoid any moisture from entering the housing.Such moisture may cause problems in accuracy of the viscositymeasurement or failure of the viscosity probe 25. Other methods to avoidcondensation or communication of moisture in relation to probe 25 arecontemplated, such as other sealing or drying arrangements, or invertinghousing 23 to allow any moisture to drain from the system. To facilitateuse in the food processing industry, a sanitary ferrule could beprovided on the inlet and outlet for a sanitary tri-clamp connection,eliminating the machining of threads on the inlet and outlet, andfacilitating access to and maintenance of the viscometer 21.

As previously indicated, the inline viscometer 21 provides actualviscosity measurements, in centipoise, of the measured material, whichmay be a batter material for example. With this and other likematerials, a problem may be created if the material is not substantiallyhomogenous during the viscosity measurement. It may therefore bedesirable to minimize such a problem, and in this embodiment, aparticulate retention or filtering system 60, as shown in FIG. 5 a, isprovided to remove particulate or non-homogenous materials from thesupply to viscometer 21. This system facilitates the viscosity readingperformed by the inline viscometer 21. Prior to entering the inlineviscometer 21, the batter is circulated through an inline filter system60. This filter system 60 removes product particles and unreacted maythat form clumps of material. The filter prevents product particles andclumps of batter from entering the housing 23 to ensure proper viscosityreadings, and to prevent such materials from contacting the ultrasonicprobe in the inline viscometer 21, which could cause physical damage tothe ultrasonic probe. The filter system 60 may be of any suitableconfiguration, but may simply be a “Y” strainer located on the in feedline to viscometer 21. The strainer may comprise a first section 62coupled to the in feed pipe 64 from the viscosity pump 26. A “Y”strainer 66 includes a strainer section 68 in which filtered materialwill collect, having an access port 70. An outlet 72 will supplyfiltered material to an outlet pipe 74. The control system may also beconfigured to operate the viscometer supply pump 26 to allow cleaning ofthe strainer section 68 without stopping the apparatus 10 duringproduction. Again, any suitable filtering system, such as is known inthe art may be used for this purpose, and this construction is merely anexample thereof.

In addition, the viscometer 21 is also susceptible to damage fromforeign objects or high-pressure fluid that it may be subjected toduring cleaning of apparatus 10. In many environments, including thefood processing industry, cleaning of the processing equipment isparticularly important. Thus, the apparatus 10 may be subjected torigorous cleaning processes, in which the sensitive viscosity sensor canbe damaged. To avoid such problems, the supply system to the inlineviscometer 21 as seen in FIG. 5 a may include a protection system 75 toprevent any foreign objects or high-pressure fluid from entering theviscometer housing 23. Any suitable system for such a purpose may beused, such as an offset piping configuration 76, comprising two shortninety-degree sections 78 and 80, on the inlet to viscometer 21. Anyother suitable barrier to such foreign objects and/or high pressurecleaning or other fluids is contemplated. The S-shape offsetconfiguration forms a trap, which is positioned before the inlet of theinline viscometer 21. The filter arrangement 60 and protection system 75facilitate the flow of the substantially homogenous batter into theinline viscometer 21 and protect the system.

As mentioned, the inline viscometer 21 is configured to provide actualviscosity measurement of the fluid passing therethrough in a continuousprocess. Desirable features of the viscometer 21 in this embodimentprovide distinct advantages. As the material to be measured flows past astationary probe, there are no moving parts, enhancing the reliabilityof the system. In the embodiment shown, the viscometer 21 is suppliedwith material in a recirculation cycle, and upon cleaning, isautomatically cleaned in place, thereby minimizing down time. Theviscometer 21 may have a broad measurement range, such as from 1 to 300cps, and may be operated continuously to allow instant response tochanges in viscosity in conjunction with the control system. Theviscometer 21 is precise, and is calibrated with a calibration fluidrather than using subjective techniques such as the Zahn cup. As will behereafter described, the viscometer 21 may also provide viscosity datato the control system or a central computer to provide a permanentrecord for quality control.

In the embodiment of the present invention as shown, the apparatus 10includes a number of level sensors or probes positioned within themixing tank 14 to monitor the level of batter therein. It has been foundthat if such sensors are coated with the batter material, and suchmaterial begins to dry, erroneous readings may result. This embodimentmay therefore include a sensor cleaning system integrated into theliquid supply system of the mixing apparatus. As shown in FIG. 6, aprobe cleaning system is disposed within the batter mixer apparatus. Asthe mixing tank 14 becomes filled with the mixture of dry batter andwater, it eventually reaches a level probes 32 near the top of themixing tank 14 to stop dispensing dry batter from the hopper 28 andwater from the water supply line 31. As mixing continues in the mixingtank 14 and continuous viscosity measurements from the inline viscometer21, batter can coat the level probes 32. The coating of the level probes32 can result in false readings, possibly causing improper delivery ofingredients to the batter applicator 20 or other problems. For example,instead of additional dry batter mix and water being added to the mixingtank 14, the batter will continue to be delivered to the batterapplicator. In the liquid supply system, water from the water supplyline 31 can be delivered into the tank 14 at the location of the levelprobes 32, ensuring that they are clear of any wet batter that may haveaccumulated and ensuring an accurate batter level reading in the mixingtank 14. This operation can be performed automatically or manually asdesired.

Turning now to FIG. 7, a simplified block diagram of the improvedcontrol system for the batter mixing apparatus of the invention isshown. The control system of the invention comprises a computerinterface mixing control system, which greatly simplifies use of themixing apparatus and allows a great amount of flexibility in theoperation thereof. Input variable parameters such as viscosity 100 andtemperature control 102 show basic parameters, which may be effectivelycontrolled by the control system. Although these parameters representbasic parameters, which can be precisely controlled in operation of thebatter mixing apparatus, a variety of other dynamic variable parametersmay be similarly controlled by selection of the desired parameters asinputs to the control system. In the preferred form, selecting inputvalues of these variables for set up of the mixing to be performed bythe apparatus may control each of the dynamic variable parametersrelating to the function of the mixing apparatus 10. A selectedviscosity value may be manually entered via a touch screen or keyboardinterfaced either integrally or selectively to an input register module104. The viscosity of the batter or other material relates to apredetermined quantity of dry and liquid ingredients, which aredeposited into the mixing tank 14. Setting of the viscosity parameterfor a mixing cycle will relate to the particular type of batter or othermaterial. It should also be understood that inputting of a selectedparameters may be performed by any suitable alternative to the keyboard,such as push buttons, limit switches or the like.

Another possible input variable as an example, is the temperaturecontrol 102, which generally refers to temperature control of thematerial in the mixing tank 14, at the applicator 20, and in thefeedback loop of the mixing system as seen in FIG. 1, or at otherlocations. The temperature controllers may be interfaced with thecontrol system of the invention, wherein the input values set for eachof these parameters at 102 will be fed to the controller andcontinuously monitored. Thus, temperature control of these variousaspects of the mixing apparatus system can be effectively accomplishedby the operation of the thermal treatment system in conjunction withindividual temperature sensors, at the mixing tank 14, the applicator20, or at other stages of processing if desired. The temperature sensorscontrollers may be interfaced with the control system of the invention,wherein the input values set for each of these parameters at 102 will befed to the controller and continuously monitored, with operation of thethermal treatment system controlled to maintain desired temperatures ofthe mixed material, incoming constituents or the like. Another aspect ofproperly mixing a batter or other material is controlling thetemperature of the input materials to tank 14. For example, if thesupply water or other fluid is not at a predetermined temperature, or ifthe temperature fluctuates, it can have adverse effects on thecharacteristics of the batter or other material. A temperature sensor tomonitor the temperature of the supply fluid or materials may allowautomatic adjustment of other parameters to compensate, alert theoperator or the like. It may also be desirable to provide the supplywater at a predetermined water pressure, which as an example, may be 24PSIG with 10 GPM capacity.

These and other pre-selected dynamic variable parameters are input intothe input register module 104, and are thereafter supplied to aprogrammable logic controller 106, which is programmed and adapted toprovide automatic operation of a batter mixing process. The PLC 106 ofthe mixing control system enables inputting and monitoring of processcontrol parameters in a user friendly and extremely flexible manner. Theprocess parameters as described above as well as any other processparameters may be initially input into the PLC 106, which has aninternal random access memory (RAM) which may be utilized to store alarge number of batter recipes or process parameters for mixing ofvarious materials, within the control system. The batter recipes or thelike may be identified by any suitable designation, wherein upon desireduse of a particular batter, the batter recipe may be downloaded from thecontrol system to automatically set up the process parameters for theparticular batter mixing operation. This will greatly reduce set up timeand minimize operator activities with respect to initiating a mixingcycle. Thus, once an acceptable batter is produced for a particularbatter recipe, the viscosity, temperature and other parameters for thatparticular batter would be established and could thereafter beprogrammed into the control system for subsequent use. Any subsequentuse would merely require inputting of a designation assigned to aparticular batter recipe to be used, wherein all process parameters andsubsequent operation of the mixing cycle would occur without operatorintervention. The PLC 106 may also have the capability to lock in theprocess parameters, wherein the operator would not be capable ofmodifying such parameters, to ensure the preservation of productintegrity as well as to facilitate diagnostic analysis and troubleshooting of any problems that may arise in the mixing process. This alsoallows the use of relatively unskilled labor to operate the system.

This system also provides the capability of generating quality controland production control reports relating to use of the batter mixingapparatus and enables the user to gather data over an extended period oftime, and trace variables relating to the mixing operation on one ormore mixing apparatus. The traceability of processing parameters givesthe user the ability to determine process controls to allow real-timeadjustment of the apparatus 10 to produce desired results. This canprovide significantly higher yields and value in light of today'sstringent tightening of quality control standards, especially in thefood industry. The use of a PLC 106 also gives the control system agreat amount of flexibility as various options may be easily added orsubtracted as the PLC 106 has available various input and outputcommunication ports for linking with various other processing devices orotherwise.

In an embodiment, the PLC 106 is operatively coupled to a digital outputmodule 108 which may generate output signals corresponding to various ofthe input process parameters. Input parameters may include viscosity100, temperature control variables 102, such as for the batter or othermaterial temperature, the cooling system temperature, the temperaturesmonitored at one or more applicators being supplied by apparatus 10, thetemperature of incoming supply materials or the like. Additionalvariables may be the set levels in the tank 14, the set parameters forthe thermal treatment system for cooling or heating the material in thetank 14, the viscosity, the set parameters for the mixer, pumps andother systems of apparatus 10, alarm set points and the like. The PLC106 may thus provide control signals to the thermal treatment system;material feed systems, pumps, mixer and other devices of the mixingapparatus 10. For example, digital output signals generated from digitaloutput module 108 may be fed through a digital to analog converter 110to generate analog signals used to set mixing process parameters.Additional process parameters may also be supplied from the PLC 106directly to the D/A converter 110 for setting of the parameters for aparticular batter recipe or the like. Output signals from the processingcircuit comprising PLC 106, digital output module 108 and the D/Aconverter 110 may thereafter be coupled to an interface circuit 112,which is adapted to interface the PLC 106 and associated processingequipment to a servo-control circuit 114 which controls and implementsmachine functions 116 and receives feedback for control of variousprocess parameters. The servo-control circuit 114 may be formed as aclosed-loop servo-control that provides dynamic feedback of measuredprocess parameters for comparison with the control inputs generated byPLC 106. The difference between the pre-selected input and the measuredoutput may then be used to drive the system toward a dynamic state whichreduces any differences to zero, so as to obtain an extremely precisecontrol of viscosity, temperature, and other parameters. Additionally,as will be described more fully hereinafter, the PLC 106 interfaced withthe servo-control circuit 114 via interface circuit 112 allows variousparameter profiles to be created in the system, wherein any deviationfrom such profiles may be indicated and used for process control as wellas information and data collection. Feedback control signals may also beprovided from the servo-control circuit 114 and coupled via interfacecircuit 112 to analog input module 118, adapted to receive variousanalog signals from measured process parameters which are converted todigital signals and fed back into PLC 106 for continuous process controland monitoring as well as data collection. Additionally, a variety ofmachine functions as well as input variables may be displayed on asuitable display device 120 for visual feedback to the machine operatoras to the status of a mixing cycle, various process parameters and avariety of other information.

Turning now to FIG. 8, there is shown a flow chart indicating set up andfunctioning of the control system in various aspects of the mixingprocess. In the control system, the PLC 106 may have a run mode and aprogram mode associated with a particular batter mixing program or othermaterial. In a food processing system as an example, a batter recipe isprepared in accordance with the process control parameters, which arefound to produce high quality product. The PLC is initially placed inprogram mode, wherein a touch screen monitor or keyboard may be used toprovide input of the various process control parameters for the batter,as may relate to a particular food product, mix material or the like.The PLC may be programmed to provide menu driven programming of a batterrecipe into the PLC. As seen in FIG. 8 a, a main menu is generated fromthe control system and PLC 106 as indicated at 130, wherein variousalternatives of system display, viscosity parameters or batter recipesprogrammed or to be programmed can be displayed.

In the system display option as seen in FIG. 8 c at 134, various processparameters including batter temperature, batter viscosity, mixing cycletime, liquid level in mixing tank, pump speeds, mixer speed, thermaltreatment system parameters, supply material parameters or the like, aredisplayed. Various functions of the batter mixing apparatus and thestatus of these functions may be displayed as indicated at 136.

Alternatively, the operator may select a display of the mixingparameters as indicated in FIG. 8 a at 130, wherein parameters such asmixing tank temperature, batter applicator temperature, supply watertemperature, batter viscosity in the mix tank, batter viscosity at thebatter applicator, mixing time, status of levels from the level probeslocated within the mix tank and other parameters as desired may bedisplayed. If an operator who is knowledgeable with respect to themixing process is implementing a mix cycle, the control system may beswitched into a run-edit mode wherein the operator can modify any of theprocess parameters, which are deemed necessary. For example, if variousexternal factors are found to affect the temperature control settings ofvarious portions of the apparatus, the operator may adjust thetemperature settings to compensate for the external factors.Alternatively, the control system may be switched into a run-only mode,wherein the process parameters may not be modified by the operator. Thisfeature essentially allows the operator to be taken out of controllingthe mixing process to ensure consistency and increase overall control ofthe mixing process. Thus, the operator does not necessarily need to beparticularly competent with respect to setting up and operating thebatter mixing apparatus to achieve high quality product and the battermixing process may be performed more cost effectively and efficiently.As all functions of the batter mixing apparatus are effectivelycontrolled by the control system, operation of the apparatus can becarried out essentially automatically.

To enable automatic operation of the apparatus, a number of mix recipesmay be programmed into and stored within the control system. Asindicated in FIG. 8 b at 132, the operator may select the mix recipeoption from the main menu 130, wherein a programmed mix process may berun, a new mix process may be created or an existing process may belisted. As indicated at 140, initiation of a mixing cycle using aprogrammed batter recipe for example, may be selected by indicating thebatter recipe to be used, wherein the control system will download theselected recipe or indicate that such a recipe does not exist.Alternatively, a process engineer or knowledgeable operator may programin a new batter recipe or edit an existing recipe, wherein each of theprocess parameters will be displayed if existing, and editing thereofcan be performed, or a new recipe may be created. As another option, anyrecipe may be listed, whereby the process parameters may be viewedaccordingly.

Prior mixing systems were also deficient with respect to operatingwithin a large scale food processing environment, wherein multipleshifts are employed to maintain the operation of the processing lineover extended periods. During such periods, either at shift changes, atthe end of production runs or otherwise, there may be the need to shutdown the mixing apparatus. In such an event, the prior systems havetypically simply been shut down at such time, with any unused batterbeing discarded. Past systems have been configured to operate tomaintain an amount of batter in the machine for use, resulting in asignificant amount of material being discarded upon these occurrences.In the present invention, an efficient shut down cycle is enabled by thecontrol system 16. At the end of a production run or other time aswarranted, a program is initiated on the mixing cycle screen of thetouch screen monitor 18 to initiate a shut down procedure. Activation ofthis program turns off the level probes located within the mixing tank14 and allows for the delivery of the batter from the mixing tank 14 tothe applicator 20 without additional dry batter mix and water beingadded to the mixing tank. This feature can significantly reduce batterwaste, such as from approximately 65 gallons down to 3-5 gallons on adaily basis. While the mixing tank is being drained during a shut downprocedure, the programmed viscosity set point is maintained.

Turning now to FIG. 9 a, an embodiment of the invention is shown,wherein a plurality of batter mixing machines may be networked togetherand operated from a central control facility to achieve distinct andadvantageous capabilities. The control system of the invention includinga PLC, has the capability of being networked with a central controlfacility as indicated at 200 and 202. The central control facility maysimply comprise a host computer, which need be no more than a standardpersonal computer having a sufficient amount of memory to handle thenumber of mixing machines on a particular network. The host computer maybe coupled to the mixing machines 10 by means of a local area network(LAN) as indicated at 204, which is adapted to communicate with the PLCof the control system for each individual mixing apparatus. LANutilizing a network interface module (NIM) as an example. The LAN isadapted to allow communication from the host computer to individualmixing machines 10 as indicated at 206. As seen in FIG. 9 b, a systemcoupled to the LAN may comprise an operator interface control station208. The operator interface provides a display for the operator on whichsystem parameters and function of the mixing machine 10 may be viewed. Aplurality of PLC's including input/output registers are shown at 210 andare coupled to the LAN 244, and forming part of the control system for aplurality of mixing machines. The individual PLC's may be programmed oredited via a programmable controller operator interface module 212 whichmay be selectively coupled to the PLC's as necessary. The PLC's may inturn be programmed to control operation of the machines 10, such as thethermal treatment systems indicated at 214 for control of thetemperature of the batter or other material as previously described.

In an example operation of the system 10, the touch-screen 18 containsall process controls and information, allowing all settings to be madeon the touch-screen. Once set, a single touch button is usable toimplement the entire mix and operation cycle of the apparatus 10. Onceelectrical, temperature control are connected and turned on, and inputwater supply is connected along with dry mix in the hopper, a mix cyclecan be initiated. As an example of the sequence of operations performedby machine 10 for production of a batter material, an operator will opena Refrigeration screen of the control system, and program the desiredtemperature. A Refrigeration Start button is actuated to allow the tankto begin chilling a heat transfer fluid prior to mixing batter. TheRefrigeration screen may also allow the operator to monitor the supplywater temperature as well as the batter temperature at the applicator20, via temperature probes. The operator then opens a Viscosity screenand programs the desired viscosity in centipoises. Thereafter, a MixCycle screen is opened, and a Mix Cycle Start button actuated. Onceactuated, the inlet water to the mix tank is initiated, until waterreaches the minimum level probe in the tank. Then the mixer, dry mix andviscosity pump 26 automatically begin mixing of the dry mix into thewater until the desired viscosity and temperature is reached. Uponreaching the programmed parameters, the system will automatically addadditional water and dry mix until the tank is full, maintaining thedesired viscosity and temperature. When the batter reaches the highlevel probe, the water and dry mix are turned off, while the mixer andviscosity pump 26 operate to maintain the desired parameters. A FeedPump screen will then be used to begin circulation of batter to theapplicator 20, and to recirculate the batter form machine 20 by means ofa return pump if desired. Setting the speed of the variable speed feedpump can control the supply of batter. The feed pump should normally bestarted when the high level probe is reached, allowing additional batterto be produced as soon as pumping of batter to applicator 20 begins. Theoperator may then go to a Tank Liquid Level screen to monitor the tankfilling operation. This screen may also indicate whether the water ordry mix is on, as well as the tank temperature. If the screen indicatesthe tank is full when it is not, the operator can press a Clean Probesbutton to remove excess batter from the level probes. Production canthen occur until operation of the machine 10 is desired to be halted,with additional water and dry mix added as needed to maintain thedesired parameters and volume of batter in the mix tank. Upon desiringto stop operation, the operator can actuate a Shut Down Cycle button,which allows the mix tank to drain. Thereafter, a Mix Cycle Stop buttonis actuated to terminate operation of the machine 10, wherein alloperations of the machine 10 are stopped, except for operation of thefeed and return pumps, which may be turned off from the dedicatedscreens. A Technical Support screen may be provided to access an AlarmList, print time for a printer, a Spare Parts List and support contactinformation if desired. The Alarm List may provide a record of alloverloads, faults, E-Stop commands or other errors or actions in anoperation cycle, along with identifying information such as date andtime for record keeping and trouble shooting. The Spare Parts Listallows a user to easily determine any spare parts required to assist inordering thereof.

Although the invention has been described relative to particularpreferred embodiments thereof, it should be apparent that variousmodifications or variations in the apparatus or details of operation arecontemplated herein and would occur to those skilled in the art. Theinvention is therefore not to be limited by the details of thedescription of the preferred embodiments, but rather is intended toencompass all such modifications, which are within the spirit and scopeof the invention as defined by the appended claims.

1. A process for preparing a food batter material and controllingviscosity of the batter material, comprising the steps of: (a) supplyingat least first and second batter components to a mix tank; (b) mixing atleast said first and said second components in said mix tank into abatter product during a mix cycle; (c) directing an amount of the batterproduct through an independent supply conduit to a viscosity controlsystem, the viscosity control system comprising an in-line viscometercoupled to the conduit to receive the batter product and substantiallycontinuously monitor the viscosity of the batter product, and returningthe product to the mix tank; and (d) control the supply of the at leastfirst and second components, and said mix cycle, to substantiallymaintain the batter product at a predetermined viscosity.
 2. The processaccording to claim 1, wherein the in-line viscometer is an ultrasonicviscometer which measures the viscosity of the batter productcontinuously.
 3. The process according to claim 1, further comprisingthe step of filtering the batter product supplied to the in-lineviscometer.
 4. The process according to claim 3, wherein the filteringof the batter product is performed after being supplied to theindependent supply conduit.
 5. The process according to claim 1, furthercomprising the step of providing an independent pump for supplying thebatter product to the in-line viscometer in a substantially uniformvolume.
 6. The process according to claim 1, wherein the batter productis supplied to a housing in which the in-line viscometer is positionedto allow the batter product to flow around the viscometer.
 7. Theprocess according to claim 6, wherein an independent pump supplies thebatter product to the housing such that the batter product flows throughthe housing without substantial pressure loss.
 8. The process accordingto claim 1, wherein the step of substantially maintaining apredetermined viscosity is performed as the batter product is suppliedto a batter applicator for application to food products, by controllingthe amounts of the first and second batter components introduced intothe mix tank to maintain a volume of batter product in the mix tank, andcontrolling the temperature of the batter product within the mix tank,with the viscosity controlled relative to a predetermined viscosity incentipoise.
 9. The process according to claim 1, further comprising thestep of monitoring the temperature of the batter product in the mix tankand controlling the temperature so as to be substantially maintainedabout a predetermined temperature.
 10. The process according to claim 1,wherein the in-line viscometer produces a signal relating to themeasurement of viscosity which is coupled to a programmable controlsystem, wherein the control system is programmed to control the mixingcycle and addition of the at least first and second components, and thetemperature of the batter product to substantially maintain the batterproduct at a predetermined viscosity.
 11. The process according to claim10, wherein the programmable control system may include a plurality ofbatter recipes stored therein, whereby an operator may select a recipeand the control system will automatically provide and maintain a batterproduct according to the selected recipe.
 12. The process according toclaim 10, wherein the control system is interfaced with other equipmentin a food processing line, and wherein parameters of operation of theother equipment or characteristics of food products being processed insuch other equipment are monitored and facilitate production of thebatter product.
 13. A process for preparing a food batter material andsubstantially maintaining a predetermined viscosity of the battermaterial, comprising the steps of: (e) supplying at least first andsecond batter components to a mix tank; (f) mixing at least said firstand said second components in said mix tank into a batter product duringa mix cycle; (g) directing an amount of the batter product to aviscosity control system, wherein the amount of batter product isfiltered prior to being introduced into an in-line viscometer formeasurement of the viscosity of the batter product; and (h) continuouslycontrolling the supply of the at least first and second components, andsaid mix cycle, based on the measured viscosity, to substantiallymaintain the batter product at a predetermined viscosity.
 14. Theprocess according to claim 13, wherein the filtering of the batterproduct provides a substantially homogenous product to the in-lineviscometer for measurement of the viscosity in centipoise.
 15. Theprocess according to claim 13, wherein the batter product isindependently pumped to the in-line viscometer to substantiallycontinuously provide a substantially uniform volume of the batterproduct to the in-line viscometer.
 16. The process according to claim13, wherein the in-line viscometer comprises an ultrasonic probe withina housing, configured such that the amount of batter product suppliedthereto substantially completely contacts the probe within the housing.17. The process according to claim 16, wherein the ultrasonic probe isdisposed in the housing in a manner which allows the material to flowaround the probe.
 18. The process according to claim 13, wherein thein-line viscometer is continuously supplied with the amount of batterproduct for viscosity measurement.
 19. The process according to claim13, wherein the in-line viscometer is intermittently supplied with theamount of batter product for viscosity measurement.
 20. A process forpreparing a food batter and controlling viscosity of the battercomprising the steps of: supplying at least a first and a secondcomponent to a mix tank; mixing at least said first and said secondcomponent in said mix tank during a mix cycle; and programming acontroller for controlling the supply of the at least first and saidsecond components, and said mix cycle to substantially maintain apredetermined viscosity through a closed loop feedback from an in-lineviscometer, and a cooling system used in conjunction with a probe formeasuring a temperature of said batter in said mix tank to substantiallymaintain said temperature of batter in said mix tank.